Processes for preparing valve metal powders, powders prepared thereby and uses therefor

1. A process comprising: melting a mixture comprising a valve metal precursor and a diluting agent in at least one first vessel under a first set of temperature and residence time conditions; transferring the mixture to at least one second vessel; and initiating, in the at least one second vessel, a reaction of the valve metal precursor to form a valve metal under a second set of temperature and residence time conditions, wherein a reducing agent is added to the at least one second vessel.

2. The process according to claim 1 , further comprising transferring the mixture from the at least one second vessel to at least one third vessel; and further mixing the mixture in the at least one third vessel under a third set of temperature and residence time conditions, wherein the reaction of the valve metal precursor to form the valve metal is continued.

3. The process according to claim 2 , further comprising transferring the mixture from the at least one third vessel to at least one fourth vessel;

and further mixing the mixture in the at least one fourth vessel under a fourth set of temperature and residence time conditions, wherein the reaction of the valve metal precursor to form the valve metal is continued.

4. The process according to claim 1 , wherein an additional mixture component selected from the group consisting of valve metal precursors, reducing agents, diluting agents and mixtures thereof is added to the at least one second vessel.

5. The process according to claim 2 , wherein an additional mixture component selected from the group consisting of valve metal precursors, reducing agents, diluting agents and mixtures thereof is added to the at least one second vessel, the at least one third vessel or both.

6. The process according to claim 1 , wherein a doping agent is added to the at least one first vessel, the at least one second vessel, or both.

7. The process according to claim 2 , wherein a doping agent is added to the at least one first vessel, the at least one second vessel, the at least one third vessel, or a combination thereof.

8. The process according to claim 4 , wherein the additional mixture component comprises a reducing agent selected from the group consisting of alkali metals.

9. The process according to claim 5 , wherein the additional mixture component comprises a reducing agent selected from the group consisting of alkali metals.

10. The process according to claim 1 , wherein the valve metal precursor comprises a component selected from the group consisting of potassium heptafluorotantalate, potassium heptafluoroniobate, and mixtures thereof.

11. The process according to claim 1 , wherein the diluting agent comprises a component selected from the group consisting of alkali halides, supercritical fluids thereof, and mixtures thereof.

12. The process according to claim 6 , wherein the doping agent comprises a component selected from the group consisting of alkali metal sulfides, alkali metal sulfones, alkali metal sulfates, and mixtures thereof.